Apparatus for producing a shaped metal product



1967 D, B. COFER ETAL 3,296,632

APPARATUS FOR PRODUCING A SHAPED METAL PRODUCT Original Filed Nov. 12,1964 4 Sheets-Sheet l INVENTORS DANIEL B. COFER ATTORNEYS Jan. 10, 1967B. COFER ETAL 3,296,632

APPARATUS FOR PRODUCING A SHAPED METAL PRODUCT Original Filed Nov. 12,1964 4 Sheets-Sheet 2 35 v -;L JJ 19 38:15 10 2 III 30 r INVENTORSDANIEL B. COFER GEORGE c. WARD BY DALE 0., PROCTER I; N I I AVTTORNEYSJan. 10, 1967 D. a. COFER ETAL 3,296,682

APPARATUS FOR PRODUCING A SHAPED METAL PRODUCT 4 Sheets$heet 3 OriginalFiled Nov. 12, 1964 A G U62 122 INVENTORS DANIEL Bv COFER GEORGE c WARDBY DALE D P ROCT ER ATTORNEYS Jan. 10, 1967 CQFER A 3,296,682

APPARATUS FOR PRODUCING A SHAPED METAL PRODUCT Original Filed Nov. 12,'1964 4 Sheets-Sheet 4 INVENTORS DANIEL B. COFER GEORGE c. WARD BY DALED. PROCTOR ATTORNEYS United States Patent Ofifice 3,296,682 APPARATUSFOR PRQDUCHQG A SHAPED METAL PRODUCT Daniel B. Cofer, George C. Ward,and Dale ll). Proctor,

Carrollton, Ga., assignors to outhwire (Jornpany, Carrollton, Ga., acorporation of Georgia Original appiication Nov. 12, 1964, Ser. No.410,805, new Patent No. 3,257,835, dated June 28, 1966. Divided and thisapplication Jan. 21, 1966, Ser. No. 522,169 7 Claims. (Cl. 29-33) Thisapplication is a division of my co-pending application Serial Number4103805 filed November 12, 1964, now U.S. Patent No. 3,257,835.

This invention relates generally to the hot forming of metal and moreparticularly to apparatus for the hot forming of metal by which oxidecoatings on the metal are eliminated and their formation precludedcontinuously and by which the temperature of the metal may beselectively controlled.

Various hot forming processes wherein metal at hot forming temperaturesis rolled, forged or otherwise worked, and subsequently cooled, are wellknown in the art. In these processes, it is highly desirable that oxidecoatings formed on the metal .prior to hot working be removed and theformation of oxide coatings on the metal during the hot working processbe prevented. It is also desirable that the temperature of the metalduring heating and cooling be constantly and accurately controlled.

Should oxide coatings be present as the metal is rolled, forged orotherwise hot formed, the oxides tend to become imbedded in the metalduring forming. Such included oxides serve to reduce the strength,ductility, and conductivity of the formed metal. Moreover, oxidecoatings on the hot formed metal produce a drab unsightly surface on themetal which interferes with subsequent working of the metal, such aswire-drawing by wearing and mutilating the drawing dies and preventingthe product from exhibiting those characteristics of strength, ductilityand conductivity generally required for commercial use of the finishedproduct.

While progress has been made in the development apparatus for hotforming metal wherein the formation of oxide coatings on the metal isprevented as the metal is being ihot formed, such methods and apparatushave not removed oxide coatings formed on the metal before the hotforming and some of which might be formed during hot forming despiteprecautions against such formations. Thus, with previous apparatus,oxide coatings were generally present on the metal after the hotforming.

Previous apparatus have generally heated the metal to hot formingtemperature at a substantial distance from the hot forming apparatus,and in transportation to the hot forming apparatus, uncontrolledtemperature changes occurred on the metal, resulting in the metalentering the hot forming apparatus at non-uniform temperatures along itslength, causing both stresses in the met-a1 as it was formed andexcessive loading conditions within the hot forming apparatus. This hasalso prevented the metal from exhibiting those characteristics ofstrength, ductility and conductivity generally required for commercialuse of the finished product.

The invention disclosed herein provides apparatus for hot forming ametal in which oxide coatings are removed were Patented Jan. 10, 1967and their formation is prevented prior to and during the hot forming andthe subsequent cooling of the metal and in which the metal is at aselected uniform hot forming temperature when the hot forming of themetal is to be initiated. More particularly, the-invention provides acontinuous controlled environment both as to temperature and removal ofoxide coatings as well as the prevention of the formation of other oxidecoatings for application in the hot forming of metal bars, ingots, orthe like into metal rods. Therefore, the invention substantiallyeliminates those problems resulting from the presence of oxide coatingsand the lack of temperature control which are associated with previousapparatus for the hot forming of metal. Moreover, the need for an acidpickle is eliminated, thus reducin operating cost.

The invention is particularly well adapted to the hot forming of acontinuously cast bar. In that embodiment of the apparatus disclosedherein, the apparatus comprises generally a tubular member into which acast bar passes as it is continuously discharged from a casting machineand in which an oxide reducing environment is maintained, a furnace intowhich the cast bar passes directly from the tubular member and in whichis provided a temperature controlled oxide-reducing environment, arolling mill for hot working the cast bar to produce rod therefrom in anoxide reducing environment into which the rolled rod passes directlyfrom the furnace, and a cooling member for cooling the rolled rod belowits oxidation temperature in an oxide reducing environment into whichthe rolled rod passes directly from the rolling mill.

While the various inventive concepts of the present apparatus is broadlyapplicable in the hot forming of a wide variety of metals and theiralloys; in particular, iron, steel, aluminum and copper are contemplatedfor working in the present apparatus. However, in the production ofoxide free, pure copper rods for subsequent wire drawing, the presentinvention is of significant value. Further, the present apparatus lendsitself to application to continuous copper bar casting equipment, theapparatus providing a fully controlled environment both as totemperature and as to a reducing medium. Thus, there is insured a clean,bright, uniformly ductile, copper rod free from included oxides orinternal stress variation and hence a product admirably suited to bedrawn as wire as the terminal operation of a single continuous processfrom continuous casting to finished wire. It is, of course, to be notedthat stress free, oxide free, bright copper rod provides ideal materialfor the drawing of wire of uniform and high quality strength, ductilityand conductivity. Further, such rods may be easily drawn with minimumpower requirements and die wear abrasion or mutilation.

A very important feature of the apparatus presented is the combination,cooperation and simultaneous action of the oxide removal from andformation prevention on the metal bar with the temperature control ofthe metal bar, each as an incident to the other. Thus, in a singleseries of successive operations, a clean, bright internally andexternally oxide free rod is produced with a substantially stress-freestructure. As more fully hereinafter discussed, the heat control gasesare produced by combustion with limited oxygen, thus producing areducing environment while effecting the desired temperature control.This is not to suggest that the method and means for the production ofan oxide-free product may not be restored to without the beneficialeffect of heat control, nor that the heat control of the invention maynot be effective and eflicient in the production of rods of uniformphysical characteristics regardless of oxides. However, in the mostadvantageous use of the principles of the invention, both desiderata areachieved by the use of the same apparatus.

The above and other features and advantages of the invention will becomeapparent from the following description when taken in conjunction withthe accompanying drawings in which like characters of referencedesignate corresponding parts throughout the several views, and wherein:

FIG. 1A is a side elevation with the cover partly broken away of therolling mill of one embodiment of the invention;

FIG. 1B is a vertical longitudinal sectional view of the furnace for usewith the rolling mill shown in FIG. 1A;

FIG. 1C is a side elevation partially broken away of the receivingmember for use with the rolling mill and furnace of FIGS. 1A and 1B;

FIG. 1D is a longitudinal sectional view of the cooling member of thepresent form of the invention;

FIG. 2 is an elevational view partly broken away of the rolling milltaken on the line 22 in FIG. 1A;

FIG. 3 is an elevational view of the supply mechanism for supplying acombustible mixture to the burner in the furnace;

FIG. 4 is a cross sectional view of the supply mechanism for supplyingnon-combustible cooling to the furnace;

FIG. 5 is an enlarged fragmentary elevational view, partially brokenaway, of the receiving member shown in FIG. 1C and of the casting wheel;

FIG. 6 is a cross section of the receiving member taken on lines 6 6 ofFIG. 5;

FIG. 7 is a schematic diagram of the control circuit for controlling theenvironment in the furnace;

FIG. 8 is a fragmentary elevational view of the rolling mill in a secondembodiment of the invention with the covers removed; and,

FIG. 9 is an elevational view taken on the line 9-9 of FIG. 8.

These figures and the following specification disclose a specificembodiment of the invention, but the details disclosed herein in no waylimit the invention since it may be embodied in other equivalent forms.

Referring to the accompanying drawings, the invention is seen tocomprise a receiving member 10, a temperature regulating furnace 11, arolling mill 12 having a cover 14 thereon and a cooling member 15. Ametal bar 16 cast in a casting machine 18 of known type shown in FIGS. 5and 6 is enclosed :by the receiving member 10 immediately upon deliveryfrom the casting machine 18. As the metal bar 16 moves through thereceiving member 10 shown in FIG. 1C, it is enveloped by a controlledenvironment, preferably reducing, but in any event non-oxidizing. Thus,in the receiving member 10, any oxide coating on the bar 16 is removedand/or its formation is substantially prevented. From the receivingmember 10, bar 16 enters the temperature regulating furnace 11 where itis heated or cooled by a controlled environment which reduces and/ orprevents from forming any oxide coating on the bar 16. Upon leaving thefurnace 11, the metal :bar 16 is received by the rolling mill 12 Withoutintermediate exposure to the ambient oxidizing atmosphere. In the mill12 the bar is again enveloped by a controlled environment which alsoreduces any oxide coating as well as prevents the formation of a newoxide coating while being rolled into rod 86. The metal rod 86 is thencooled below its oxidation temperature in the cooling member 15 by acontrolled environment that reduces any oxide coating and prevents thefurther oxidation of the metal.

Referring more particularly to FIG. 16, the receiving member 10 is seento comprise an extractor chamber 19,

a transfer chamber 20, and a flexible connector 21. The extractorchamber 19 is an arcuate member substantially square in cross-section asis best shown in FIGS. 5 and 6, the sides 24a of which extend adjacent acasting wheel 22 of the casting machine 18 and up and over the wheel 22.Cover members 24 extend between the sides 24a from just outwardly of theouter periphery of the casting wheel 22 thereby completing a channel 25through which the metal bar 16 may move upon being extracted from thecasting wheel 22. A slot 26 in the outer cover member 24 allows a metalband 28, which encircles the casting wheel 22 to form a casting mold, topass out of the channel 25 through the extraction chamber 19 so that themetal bar 16 may be extracted from the casting wheel 22 into the channel25 of the extraction chamber 19 without contacting the outsideatmosphere. Seals 29 adjacent the metal band 28 as it passes through theslot 26 prevent the atmosphere outside of the extraction chamber 19 fromentering the channel 25 in the extraction chamber 19. At the lower endof the outer edge member 24 as viewed in FIG. 5 is a seal 30 which alsoserves to help keep the outside atmosphere from the channel 25.

The flexible connector 21 is a hollow bellows member attached to theupper free end of the extractor chamber 19 along a centerline collinearwith that of the extractor chamber 19 at its one end and with that ofthe transfer chamber 20 at its other end. The connector 21 allows themetal bar 16 to pass from the extractor chamber 19 to the transferchamber 20 without contacting the atmosphere outside the receivingmember 10. The connector 21 also allows the extraction chamber 19 to bemoved to a plurality of positions with respect to a support member 3%)by the operation of an adjusting cylinder 31 attached to the extractorchamber 19 and the support member 30 while allowing the transfer chamber20 to remain stationary.

The transfer chamber 20 is a cylindrical hollow member, the centerlineof which is substantially horizontal, comprised of a metal side wall 32having a circular metal end 32a bolted thereto aand having insulation 34on the interior thereof to substantially prevent the transfer of heatfrom the metal bar 16 to the environment outside the receiving member10. The metal bar 16 passes from the connector 21 into a channel 35 ofthe transfer chamber 29, through an opening 36 through the end 32a andthe insulation 34, where it is received by rolls 38 which keep the metalbar 16 aligned for passage into the transfer chamber 26. A plurality ofsupport rolls 39 transfer the metal bar 16 through the transfer chamber21 while maintaining the metal bar 16 substantially straight. Pinchrolls 40 receive the metal bar 16 at the delivery end 41 of the transferchamber 20 and align the bar 16 for passage through an opening 42 in thefurnace 11.

An inert or reducing environment is introduced into the channel 35 ofthe transfer chamber 20 through a supply pipe 44 joining the channel 35with an inert or reducing enviroiunent supply (not shown) such as a gasgenerator. A valve 45 regulates the rate at which the inert or reducingenvironment is introduced into the channel 35. The inert or reducingenvironment flows around the metal bar 16 in the chanel 35, through theopening 36 into the flexible connector 21, through the connector 21 andthe extraction chamber, and out of the extraction chamber 19 adjacentthe sides of the casting wheel 22. Thus, the metal bar 16 is envelopedby an inert or reducing environment from the time it leaves the castingmachine 18 and while it passes through the receiving member 10.

Attached to the delivery end 41 of the transfer chamber 20 is thetemperature regulating furnace 11 shown in FIG. 1B, the centerline ofwhich is collinear with that of the transfer chamber 20. The furnace 11comprises generally a tubular side wall 46 and circular end plates 48attached to each end of the side wall 46. A refractory lining 49 coversthe inside of the side wall 46 and the end plates 48 to preventdeterioration of the side wall 46 and the end plates 48 due to the heatof a direct flame within the furnace 11. An opening 42 in each end plate48 and the lining 49 allows the metal bar 16 to pass from the transferchamber through a channel 51 defined by the refractory lining 49.

In order to properly maintain the metal bar 16 at a uniform temperatureat the entrance to the rolling mill 12, it is necessary at times to addheat to the metal bar 16, and at other times to cool the metal bar 16.It is also necessary that any oxide coating that may have formed on themetal bar 16, in the absence of or despite the receiving member 10,during passage from the casting machine 22 to the furnace 11 be reducedor removed from the metal bar 16 before passage into the rolling mill22.

Heat to raise the temperature of the metal bar 16 is supplied to thefurnace 11 by a conventional gas burner 52 positioned within the channel51 of the furnace 11, said burner having a tubular wall 54 withapertures 55 therethrough to allow a combustible reducing gas mixture toenter the channel 51 for combustion. This reducing mixture reduces anyoxide on metal bar 16 as the mixture burns. A supply line 50communicating with the burner 52 and a supply pump 56 supplies theburner 52 with the combustible reducing mixture. The pump 56 receivesthe combustible reducing mixture at a constant air-fuel ratio from ametering system 58 such as an industrial carburetor which furnishes aconstant air-fuel ratio mixture regardless of the gas supply. Byregulating the output of the pump 56, as will be explained later, theamount of mixtureentering the burner 52 and therefore the amount of heatproduced by the burner 52 can be regulated. Thus, the combustiblereducing mixture supplied to the burner 52 by the metering system 58reduces any oxide on the metal bar 16 as it passes through the furnace11 so that only the original cast metal of the bar 16 is left afterpassage through the furnace 11.

In order to impart to the furnace 11 the ability to cool the metal bar16 while still reducing any oxide coatings on the metal bar 16, areducing environment comprised of the products of combustion is suppliedthrough a pipe 59 and a manifold 61 The reducing environment is producedin a precombustion chamber 61 external of the furnace 11 and is suppliedwith a combustible mixture having an air-fuel ratio such that theproducts of combustion will reduce oxide coatings. This reducing mixtureis supplied to the precombustion chamber 61 through a constant air-fuelratio burner 62 of known type. The combustible reducing mixture is thenburned in the chamber 61 and the products of combustion, which are alsoreducing, are pumped into the furnace 11 by a transfer pump 64 of knowntype through the pipe 59. A water jacket 66 around the pipe 5? serves tocool the products of combustion as they flow through the pipe 59 to thepump 64. A water pump 68 of known type provides a regulated water supplyto the water jacket 66 and a discharge pipe 69 allows the water to beremoved from the water jacket 66. The regulation of the amount of flowthrough the burner 62, the transfer pump 64 and the water .pump 68 willbe explained in the following discussion on the control system for thefurnace 11.

In practice, the reducing atmosphere has been produced by the combustionof an oxygen starved mixture of air and natural gas. Other fuel may, ofcourse, be substituted. The combustion of this rich mixture is, ofcourse, incomplete in the absence of additional oxygen, thus producing areducing environment. In the present method and apparatus, additionaloxygen is supplied by the oxide of the metal which, in supplying theoxygen for more complete oxidation, is reduced to the pure metal.

Referring to FIG. 7, the control system for the furnace 11 of thepresent invention is seen to comprise a voltage regulator 121, apressure switch 122 and a temperature limiting switch 120. The voltageregulator 121 is connected to a constant voltage input which is standardline voltage and varies the output voltage therefrom in accordance withthe voltage produced by a thermocouple 123 positioned within the channel51 in the furnace 11; the pressure switch 122 activates the transferpump motor 64' when the voltage drop across a pressure pickup 124positioned within the channel 57 of the furnace 11 becomes suflicientlygreat; and the temperature limiting switch starts or stops the supplypump motor 56', the burner motor 62, transfer pump motor 64' and thewater pump motor 68' in accordance with the voltage output from athermocouple as will be explained later. The thermocouples 123 and 125are the voltage sources of radiation pyrometers of known type and arepositioned so that the temperature of the metal bar 16 is indicated justas it enters the furnace 11. If the temperature of the metal bar 16 isbelow a certain predetermined temperature, then the voltage output fromthe thermocouple 125 activates the supply pump motor 56' through theswitch 120. The pump 56 then supplies a reducing combustible mixture tothe burner 52 in accordance with the voltage output from the voltageregulator 121, an increase in fuel being supplied varying inversely withan increase in the temperature of the bar 16. The voltage output fromthe voltage regulator 121 is regulated by the voltage output from thethermocouple 123 and, if the temperature of the metal bar 16 is abovethe predetermined temperature, the voltage from the thermocouple 125causes the switch 120 to turn the supply pump motor 56 off, therebystopping combustion within the furnace 11 due to fuel starvation.

If the temperature of the metal bar 16 is above the predeterminedtemperature, the voltage output from the thermocouple 125 activates theburner 62, the water pump 68 and the transfer pump 64 through the switch120. The voltage output from the thermocouple 123, through the voltageregulator 121, controls the speed of the constant air-fuel ratio burnermotor 62 in order to control the burning rate in the burner 62, thewater pump motor 58' in order to control the flow of water through thewater jacket 66 and the transfer pump motor 64' to control the rate offlow of the gases of combustion from the precombustion chamber 61 intothe furnace 11. The flow of water through the water jacket 66 cools thegases of combustion sufficiently so that they will cool the bar 16 tothe predetermined temperature before reaching the rolling mill 12.Therefore, the higher the temperature of the metal bar 16, the more flowof water that is produced by the pump 68 in order to cool the metal bar16 to the predetermined temperature. hf the temperature of the metal bar16 drops below a predetermined temperature, the voltage output from thethermocouple 125, through the limiting switch 120, turns oft the motors62', 68 and 64'. In case of failure of one of the pumps 56' or 62', avoltage from the pressure pickup 124 activates the transfer pump motor64' toclear the furnace 11 of combustible gases that may result in anexplosion if allowed to remain in the channel 51.

The furnace 11, then, supplies heat to the metal bar 16 by burning acombustible mixture supplied to the channel 51 by the burner 52 thatproduces a reducing environment in the channel 51 around the metal bar16 if the metal bar 16 is below the predetermined temperature and inaddition reduces any oxidation that may be present on the metal bar 16.Furthermore, the furnace 11 supplies cooled gases to the channel 51 ifthe metal bar 16 is above the predetermined temperature that not onlycool the metal bar to the predetermined temperature but also reduce anyoxide coating that may be present on the metal bar 16. Moreover, thefurnace 11 may be used to present an oxide free metal bar 16 to therolling mill 12 at a predetermined rolling temperature to the exclusionof the receiving member 10 if a sufficient amount of reducing gases isintroduced into the channel 51. This requires the use of an uneconomicalamount of fuel, however, resulting in a need for the transfer member 10.

In order to remove any flash material from the corners of the metal bar16, a plurality of flame scarfers 131 are provided within the furnace11, The flame scarfers 131 comprise a plurality of nozzels 132protruding through the side wall 46 and refractory lining 4.9 of thefurnace 11, a plurality of mixture supply pipes 133 communicating withthe nozzles 132, a manifold 134 which distributes a combustible mixtureto the pipes 133, and a valve 135 in the manifold 134 which regulatesthe flow of mixture to the nozles 132. The nozzles 132 are positioned sothat the jet of flame from the nozzle 132 is directed against thecorners of the metal bar 16 and burn the flash metal away.

A pair of pinch rolls 70 enclosed within a metal tube 71 extendingbetween the end plate 48 and an end panel 72 of the rolling mill 12receives the metal bar 16 as it exits the furnace 11 through the opening42 in the end plate 48 and guide it through the passage '74 in the endpanel 72 to the rolling mill 12. The metal tube 71 serves to prevent anycontact of the heated metal bar 16 with the environment outside thepresent apparatus and provides support for the pinch rolls 70.

The rolling mill 12 shown in FIG. 1A is of generally conventional typewith a cover 14 installed thereon to allow a slight fluid pressure to beexerted on the inside thereof. The cover 14 comprises a. plurality of L-shaped hoods 75 extending out and over the roll stands 76 of the rollingmill 12 and seated at their ends against the base of L-shapedtransmission housing '78 of the rolling mill 12, and end panels 72 atthe entrance end 80 and the exit end 81 of the rolling mill 12. Thehoods 75 are hinged, as .at 79, at their upper ends to the top of thehousing 7 8 as seen in FIG. 2 and have handles 32 adjacent their lowerends so that each hood 75 can be easily raised by hand in order to workon the roll stands 76. The hoods 75 are mounted adjacent each other sothat there is very little opening between their edges 84, thuspermitting little flow of environmental gases to or from the inside ofthe cover 14. The end panels 72 are mounted on the transmission housingso that they communicate with the hoods 75 to form a substantiallyclosed chamber 85 through which the metal bar 16 passes. The passages 74in the end panels 72 allow the metal bar 16 to enter the rolling mill12, be rolled in the rolling mill 12, and exit from the rolling mill 12as rod 86.

A lubricating coolant manifold 88 extends along the length of therolling mill 12 above the roll stands 76 as viewed in FIGS. 1A and 2 andserves to distribute a lubr-icating coolant to the rolls 89 of therolling mill 12 and the metal bar 16 through nozzles 92 as the bar 16passes through the rolling mill 12. The coolant is supplied to themanifold 88 by a pipe 90 having a valve 91 interposed therein toregulate the flow of coolant through the manifold 88 and the nozzles 92.A low pressure is created within the chamber 85 by the vaporization ofthe coolant by the heat of the metal bar 16 and the rolls 89. However, amanifold 94 having a plurality of nozzles 95 spaced thereal-ong allows areducing mixture, as above referred to, to be introduced under pressureinto the chamber 85, thus producing an even greater differential betweenthe pressure in the chamber 85 and the pressure of the outsideatmosphere. A supply pipe 96 having a flow rate control valve 98delivers the reducing mixture to the manifold 94 in regulated amounts.Thus, no external atmosphere is permitted to enter the chamber 85 withinthe hoods 75.

Referring to FIGS. 8 and 9, the second embodiment of the rolling mill 12shown in FIG. 1A is seen to compr-iw a rolling mill 12' wherein themetal bar 16 is received from the furnace 11 by a transfer tube 71'. Themetal bar 16 is then rolled in the rolling mill 12 in the usual mannerwith the metal bar 16 being transferred between roll stands 76 throughadditional transfer tubes 71. The flow of coolant is provided by acoolant manifold 88 having a plurality of nozzles 92' therealong, asupply pipe 90, and a valve 91'. The flow of coolant from the nozzles 92is sufficient to envelope the bar 16 as it is being rolled so as topreclude the outside environment from contacting and oxidizing the metalbar 16 as it is being rolled. Heat from the roll stand 76' and the metalbar 16 causes the coolant to be oxidized during the rolling of the bar16 which, in turn, reduces any oxides that might be present on the metalbar 16.

As the rolled rod 86 leaves the rolling mill 12, it it received by acooling tube 99 having three segments 99a, 99b and 990, each having apassage 98 therethrough. The first segment 99a communicates with thechamber 85 through the passage 74 in the end panel 72 at one end andwith a catch basin 100 at its other end. The catch basin 100 is a hollowrectangular member provided with a drain pipe 101 at its lower end fordraining any fluid caught in the catch basin 100. The second segment99!: of the cooling tube 99 communicates with the catch basin 100opposite from the first segment 99a so that the passage 98 in the firstsegment 99a and the passage 98 of the second segment 99b are collinear.A trumpet shaped entrance to the passage 98 in the second segment 99bfacilitates the entrance of the rod 86 into the second segment 9%.

The extending end of the second segment 9% communicates with aninjection block 105 having a central passageway 106 ther-eth-rough. Anannular recess 108 in the block 105 communicates with the passageway 106and a plurality of coolant inlet pipes 107 for supplying coolant to theannular recess 108. A conical recess 110 extends from the annular recess108, along the cetnral passageway 106 towards the second segment 99b.Threadedly inserted into the block 105 and extending into the conicalrecess 110 is a metering pin 111 which has a tapered end 112corresponding to the conical recess 110. A central channel 113 throughthe metering pin 111 is aligned with the central passageway 106 so thatthe rod 86 may pass therethrough.

Adjusting the metering pin 111 so that the tapered end 112 extends intothe conical recess 110 regulates the amount of coolant allowed to flowalong the recess 110 into the central passageway 106 from the annularrecess 108. Thus, the flow velocity of coolant into and along thecentral passageway 106 and along the passageway 98 of the second segment9% toward the rolling mill 12 is regulated by turning the metering pin111 within the block 105. Decreasing the spacing between the recess 110and the end 112 of the metering pin 111 increases -the velocity of theflow of coolant into the central passageway 106, and increasing thespacing between the recess 110 and the metering pin 111 decreases thevelocity of the flow of coolant int-o the central passageway 106. Thecoolant flows along the passageway 98 of the segment 9% and into thecatch basin 100 where it is removed. The coolant within the cooling tube99 is oxidized by the heat of the metal rod 86 thereby producing areducing atmosphere which reduces any minute oxide coatings that mayhave reformed on the metal rod 86 subsequent to rolling.

Another catch basin 100' similar to the catch basin 100 is attached tothe opposite end of the block 105 and communicates at its opposite sidewith an air wipe block 116. The opposite end of the metering pin 111 hasa tapered shoulder 114 thereon which extends into a conical recess 115of the air-wipe block 116. The airwipe block 116 has a plurality ofangularly disposed ports 118 therein communicating with a rod passageway119 through the block 116 at their one end and a plurality of air supplytubes 120 at their other end. The ports 118 are positioned so that airor some other similar gas flowing from the supply tubes 12 through theports 118 is directed along the passageway between the shoulder 114 onthe metering pin 111 and the conical recess 115 and against the rod 86so that any coolant remaining on the rod 86 is removed. Therefore, anycoolant on the rod 86 as it leaves the central channel 113 through themetering pin 111 is blown away from the rod 86 and into the catch basin100 by the fluid flowing from the ports 118 and along the passagebetween the metering pins 111 and the recess 115.

The rod 86 then enters the third segment 990 of the cooling tube 99cooled below its oxidation temperature. The rod 86 also possessesdesired hot rolled characteristics due to the temperature control and istherefore ready for subsequent drawing, coiling, or storing operationsin an unox-idized condition.

Operation In operation, the metal bar 16 enters the channel 25 of theextraction chamber 19 from the casting wheel 22 where it is immediatelyenveloped by an inert or reducing environment flowing oppositely alongthe channel 25 to the direction of motion of the metal bar 16. Thus, themetal bar 16 is not subjected to environmental conditions which tend tooxidize the metal bar 16 as it is extracted from the casting wheel 22 ofthe casting machine 18 and/or with a reducing medium scale which may beformed on the bar during casting will be reduced. It is also understoodthat the extraction chamber 19 may be easily modified to receive themetal bar 16 as it is cast by other types of casting machines known inthe art and thereby prevent oxidation of the metal bar 16 as it isdelivered from such other types of casting machines.

The metal bar 16 passes along the extraction chamber 19, through theflexible connector 21 and into the transfer chamber 20 where it isgrasped by the rolls 38, all the while being enveloped by the inert orreducing environment supplied by the pipe 44 to the transfer chamber 20.The metal bar 16, after leaving the rolls 38, passes along the transferchamber 20 on the support rolls 39, is received by the pinch rolls 40and aligned for entrance into the temperature control furnace 11.Radiant heat loss from the bar 16 is substantially prevented during thepassage of the bar 16 through the transfer chamber 29 by the insulation34 on the inside of the transfer chamber 19. Thus, both oxidation andradiant heat loss from the bar 16 are substantially prevented during thepassage of the metal bar 16 through the receiving member 19 by the inertor reducing environment and the covering 34.

The metal bar 16 enters the furnace 11 where it is heated or cooleduntil the predetermined hot working temperature is reached, and theflash metal on the edges thereof is removed by the scarfers 131. Thethermocouples 123 positioned at the entrance of the furnace 11 sense thetemperature of the meal bar 16 as it enters the furnace 11 and transmitsan electrical signal to the voltage supply 121 which regulates thevoltage to the motors 62, 64', 56 and 68' in accordance with thetemperature of the bar 16. The temperature limiting switch 120 activatesthe motors 62', 64' and 68', while stopping the motor 56 if thetemperature of the metal bar 16 is above the predetermined temperatureand activates the motor 56, while stopping the motors 62', 64' and 68 ifthe temperature of the metal bar 16 is below the predeterminedtemperature. Thus, the temperature of the metal bar 16 is automaticallyregulated as it passes through the furnace 11. Also, any oxidation thatmay have formed on the metal bar 16 is quickly and effectively reducedso that the bar 16 enters the rolling mill 12 via the pinch rolls 70 inan oxide free state, thereby alleviating the problems encountered whenthe rolling is performed on oxide coated bars. The furnace 11 is capableof reducing the oxide coating on the metal bar 16 even if no oxidationprevention is provided by a means between the casting machine 22 and thefurnace 11 if large quantities 10 of fuel are added to the furnace 11,although this is uneconomical and is only used if a failure developes inthe receiving member 19.

The metal bar 16 is aligned by the pinch rolls 70 and enters the rollingmill 12 for rolling. The bar 161s then rolled into rod 86 by the rolls89 while coolant is supplied by the nozzles 92 to maintain thetemperature of the metal bar 16 at the proper rolling temperature duringthe rolling operation. The coolant is partially oxidized by the heatfrom the metal bar 16 and the rolls 89 and creates a slight pressuredifferential across the cover 14. Thus, oxidation of the metal bar 16 isprevented. Moreover, the pressure within the chamber can be supplementedby the reducing environment introduced under pressure by the nozzles 95.Since the burning of the coolant produces a reducing environment in thevicinity of the surface of the metal bar 16, this prevents the formationof oxide coatings while the bar 16 is being rolled and also reducesminor oxidation that may be encountered on the surface of the bar 16.

The rod 86 leaves the rolling mill 12 at an elevated temperature andpasses into the cooling tube 99 wherein an environment which is reducingenvelopes the rod 86 and cools it below its minimum oxidationtemperature. The coolant flows from the recess 108 along the spacebetween the recess 110 and the metering pin 111 and envelopes the rod 86as it flows along the central passageway 106 and the passageway 98oppositely to the motion of the rod 86 to the catch basin where it isremoved.

The rod 86 extends past the air-wipe block 116- wherein the air blastfrom the ports 118 removes any of the coolant remaining on the rod 86.The rod 86 is then ready for subsequent coiling or drawing operationswithout danger of oxidation.

In using the second embodiment of the present invention, all of theapparatus for the process is the same except the rolling mill 12' inplace of the rolling mill 12. The rolling mill 12 receives the cast bar16 from the furnace 11, rolls the bar 16 into rod 86 while envelopingthe bar 16 and rod 36 with a reducing environment supplied by the burnedcoolant from the manifold 88 and nozzles 92 and discharges the rod 86int-o the cooling tube 99 for cooling in the aforementioned manner.

The rod 86, then, is received from the third segment 990 of the coolingtube 99 in an oixde free state and possessing the desired hot rolledcharacteristics as to strength, ductility and conductivity as a resultof proper temperature control supplied by the present invention.

It will be obvious to those skilled in the art that many variations andapplications may be made in the embodiments chosen for the purpose ofillustrating the present invention without departing from the scopethereof as defined by the appended claims.

What is claimed as invention is:

1. Apparatus for producing a shaped metal product comprising:

(A) casting means including a casting wheel having a peripheral groove,a band cooperating with said groove of said casting wheel to form a moldcavity, and a means for introducing molten metal to said mold cavitywhereby cast metal is obtained,

(B) working means for working said cast metal into a shaped product,

(C) and enclosure means having an inert environment for enclosing saidcast metal from the region of takeoff from said casting wheel to aregion beyond said working means, said enclosure means including anentrance means adapted to immediately receive said cast metal from saidmold cavity.

2. The apparatus of claim 1 wherein said entrance means includes anarcuate chimber adapted to sealingly engage the periphery of saidcasting wheel in the region of take-off of said cast metal from saidcasting wheel.

3. The apparatus of claim 1 wherein said enclosure means includes afirst chamber portion extending from said 1 1 casting wheel to saidworking means, a second chamber portion associated with said workingmeans, and a third chamber portion extending beyond said working means.

4. The apparatus of claim 3 wherein said third chamber portion includesmeans for cooling said shaped product.

5. The apparatus of claim 3 wherein said working means includes arolling mill having a plurality of roll stands and said second chamberportion includes a cover enclosing said roll stands.

6. The apparatus of claim 1 wherein said apparatus includes adjustingmeans for adjusting the temperature of said cast metal between saidcasting means and said Working means.

7. The apparatus of claim 6 wherein said adjusting means is selectivelyresponsive to the temperature of said cast metal at a predeterminedpoint between said casting means and said Working means.

References Cited by the Examiner UNITED STATES PATENTS 1,968,442 7/1934Clark 7238 2,359,453 10/1944 Waldron 29-333 RICHARD H. EANES, JR.,Primary Examiner.

1. APPARATUS FOR PRODUCING A SHAPED METAL PRODUCT COMPRISING: (A)CASTING MEANS INCLUDING A CASTING WHEEL HAVING A PERIPHERAL GROOVE, ABAND COOPERATING WITH SAID GROOVE OF SAID CASTING WHEEL TO FORM A MOLDCAVITY, AND A MEANS FOR INTRODUCING MOLTEN METAL TO SAID MOLD CAVITYWHEREBY CAST METAL IS OBTAINED, (B) WORKING MEANS FOR WORKING SAID CASTMETAL INTO A SHAPED PRODUCT, (C) AND ENCLOSURE MEANS HAVING AN INERTENVIRONMENT FOR ENCLOSING SAID CAST METAL FROM THE REGION OF TAKE-